Reinforced thermosetting resin structure with integral unflanged nozzle and method

Abstract

A method and apparatus for fabrication of nozzles on reinforced thermosetting resin structures, more particularly, a method and apparatus for fabricating nozzles on pipe headers. A main pipe section is provided with a through branch outlet, and a shaped mold is provided to fit through the outlet and to provide a form for molding of the desired nozzle. Parts of the main pipe section which are adjacent to the mold are chamfered on the outside. Resinous matrix laminates are then provided to cover the mold and adjacent parts of the main pipe section. The method provides a smooth corrosion resistant interior joint between the pipe header and the new nozzle, with a new primary laminate providing both corrosion resistance and strength properties comparable to preformed pipe parts of the same resinous matrix laminate materials.

I claim: 
     
       1. A fibre reinforced resin structure comprising: a. a primary structure comprising a primary wall having an interior primary surface and an exterior primary surface, and having a through branch opening defined by a circumferential wall edge portion, said wall edge portion having an interior primary edge surface portion of said interior primary surface,   b. an integrally formed branch structure comprising: i. a generally annular branch portion having an interior branch surface defining a branch passageway, and   ii. an annular transition portion which is integrally formed with said branch portion and which has an interior annular transition surface which in peripheral cross section has a convex curvature and which forms with said branch surface a substantially continuous and uninterrupted surface, said transition portion having a branch structure bonding surface which is positioned against and is bonded to a matching primary bonding surface of said primary structure, with said interior annular transition surface meeting said interior primary surface at a juncture line, with adjacent areas of said interior annular transition surface and said interior primary surface forming a continuous and aligned surface region.     
     
     
       2. The structure as recited in claim 1, wherein said primary structure has an interior corrosion resistant layer defining said interior primary surface, and said branch structure has an interior corrosion resistant layer providing said branch surface and said interior annular transition surface. 
     
     
       3. The structure as recited in claim 2, wherein said interior corrosion resistant layers comprise resin. 
     
     
       4. The structure as recited in claim 2, wherein the interior corrosion resistant layer of said branch structure extends from said juncture line over said matching primary bonding surface so as to be bonded thereto. 
     
     
       5. The structure as recited in claim 4, wherein said matching primary bonding surface is a champhered surface which has a slant of no greater than 45° relative to said interior primary surface, and meets said interior primary surface at said juncture line. 
     
     
       6. The structure as recited in claim 5, wherein said angle is less than 45°. 
     
     
       7. The structure as recited in claim 6, wherein said angle is less than 30°. 
     
     
       8. The structure as recited in claim 7, wherein said angle is less than 20°. 
     
     
       9. The structure as recited in claim 1, wherein said primary structure is a pipe. 
     
     
       10. The structure as recited in claim 1, wherein said matching primary bonding surface is a champhered surface which has a slant of no greater than 45° relative to said interior primary surface and meets said interior primary surface of said juncture line. 
     
     
       11. The structure as recited in claim 10, wherein said angle is less than 45°. 
     
     
       12. The structure as recited in claim 11, wherein said angle is less than 30°. 
     
     
       13. The structure as recited in claim 12, wherein said angle is less than 20°. 
     
     
       14. A fibre reinforced resin structure comprising: a. a primary structure comprising a primary wall having an interior primary surface and an exterior primary surface, and having a through branch opening defined by a wall edge portion, said wall edge portion having an interior primary edge surface portion of said interior primary surface and a champhered exterior surface portion extending at a slant from said exterior primary surface inwardly toward said branch opening to meet said interior primary surface portion at an edge line and forming an angle with said interior primary surface portion of less than 45°;   b. a branch structure comprising a branch wall having an interior branch surface which is spaced from said wall edge portion and which is aligned transversely relative to said interior primary surface;   c. a transition structure joined to said primary structure and said branch structure, said transition structure having an annular configuration and an interior annular transition surface which in peripheral cross section has a convex curvature and has a sloping transition structure bonding surface which is positioned against and is bonded to said champhered exterior surface portion, with said annular transition surface meeting said interior primary edge surface portion at a juncture line, and with adjacent areas of said interior annular transition surface and said interior primary edge surface portion forming a continuous and aligned surface region.   
     
     
       15. The structure as recited in claim 14, wherein said primary structure has an interior corrosion resistant layer defining said interior primary surface, said branch structure has an interior corrosion resistant layer providing said branch surface and said transition structure has a corrosion resistant inner layer defining said interior transition surface. 
     
     
       16. The structure as recited in claim 15, wherein the interior corrosion resistant layer of said transition structure extends from said juncture line over said champhered exterior surface portion so as to be bonded thereto. 
     
     
       17. The structure as recited in claim 16, wherein said interior corrosion resistant layers comprise resin. 
     
     
       18. The structure as recited in claim 17, wherein said angle is less than 20°. 
     
     
       19. The structure as recited in claim 14, wherein said primary structure is a pipe. 
     
     
       20. The structure as recited in claim 14, wherein said angle is less than 20°.